Rotation mechanism for key blade

ABSTRACT

A key fob assembly for a vehicle that includes a housing is provided. A mechanical key includes a key holder for rotation to and from the housing. The key holder includes first and second ends positioned opposite to each other. The key holder defines an opening extending between the ends for defining a pivot axis to facilitate the rotational movement of the mechanical key. The spring cover is coupled to the key holder and positioned about the second end of the opening. The spring is positioned within the opening and is coupled to the spring cover. The button is coupled to the spring and is releasably coupled to the first end for preventing rotational movement of the key holder when the button is coupled to the first end and for facilitating rotational movement of the key holder about the pivot axis when the button is released from the key holder.

BACKGROUND

1. Technical Field

The embodiments of the present invention generally relate to a remote keyless entry (RKE) fob having a rotatable key blade for a vehicle.

2. Background Art

A number of key fobs have been developed which include rotatable key blades. In one conventional approach, a user may manually grasp the key blade and rotate the key blade from out of a housing of the key fob in the event the key blade is needed to start an engine of the vehicle. In another conventional approach, the key fob may include a button which actuates one or more mechanisms for projecting the key blade from the housing of the key fob. The user may simply fold the key blade back into the housing of the key fob when it is necessary to stow the key blade when not in use.

With the key fob configuration having the button for actuating the key blade, the shape of the button is limited to being circular such that the button is configured to rotate with the key blade as the key blade is rotated from the housing of the key fob. Vehicle designers have no option but to provide circular buttons which limit the design capability of the key fob. Various automotive manufacturers desire to implement stylistic key fobs to consumers as such manufacturers recognize that the consumers associate a social status to the appearance of the key fob. These consumers want the style and appearance of the key fob to be commensurate with the style and design of the particular vehicle they drive.

SUMMARY

In at least one embodiment, a key fob assembly comprising a housing, a plurality of electrical components, a mechanical key, a spring cover, a spring, and a button is provided. The plurality of electrical components are positioned within the housing for transmitting radio frequency signals to a vehicle. The mechanical key includes a key holder for rotation to and from the housing. The key holder includes first and second ends positioned opposite to each other and the key holder defines an opening extending between the ends for defining a pivot axis to facilitate the rotational movement of the mechanical key. The spring cover is coupled to the key holder and positioned about the second end of the opening. The spring is positioned within the opening and is coupled to the spring cover. The button is coupled to the spring and is releasably coupled to the first end for preventing rotational movement of the key holder when the button is coupled to the first end and for facilitating rotational movement of the key holder about the pivot axis when the button is released from the key holder.

In another embodiment, a key fob assembly comprising a housing, a mechanical key, a spring cover, a spring, and a button is provided. The plurality of electrical components are positioned within the housing for transmitting radio frequency signals to a vehicle. The mechanical key includes a key holder for rotation to and from the housing. The key holder includes first and second ends positioned opposite to each other and the key holder defines an opening extending between the ends for defining a pivot axis to facilitate the rotational movement of the mechanical key. The spring cover is coupled to the key holder and positioned about the second end of the opening. The spring is positioned within the opening and is coupled to the spring cover. The button is coupled to the first end of the key holder and to the spring for preventing rotational movement of the key holder. The button is releasable from the key holder in response to a force and is linearly moveable from the first end to the second end to compress the spring such that the spring causes the key holder to rotate about the pivot axis for rotating the mechanical key.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments of the present invention are pointed out with particularity in the appended claims. However, other features of the various embodiments will become more apparent and will be best understood by referring to the following detailed description in conjunction with the accompany drawings in which:

FIGS. 1 a-1 c depict a key fob assembly and various positions of a key blade with respect to the key fob assembly;

FIG. 2 depicts an exploded view of the key fob assembly;

FIGS. 3 a-3 e depict perspective views of the key fob assembly while in the process of being assembled; and

FIGS. 4 a-4 b depict the position of the release button when the key blade is in a fully deployed state and in a fully stowed state.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

As required, detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.

Moreover, except where otherwise expressly indicated, all numerical quantities in this description and in the claims are to be understood as modified by the word “about” in describing the broader scope of this invention. Practice within any numerical limits stated is generally preferred. Also, unless expressly stated to the contrary, the description of a group or class of materials by suitably or preferred for a given purpose in connection with the invention implies that mixtures of any two or more members of the group or class may be equally suitable or preferred.

The embodiments of the present invention sets out to provide, among other things, a non-rotatable release button as used in connection with a key fob and a mechanical key. Such a characteristic may allow designers to utilize the non-rotatable characteristic so that generally non-circular release buttons may be incorporated with key fobs to satisfy market demand for aesthetically appealing key fobs. It is contemplated that the embodiments of the present invention may also be used in connection with circular release buttons.

Referring now to FIGS. 1 a-1 c, a key fob assembly 10 and various positions of a mechanical key 15 with respect to the key fob assembly 10 are illustrated in accordance to one embodiment of the present invention. The key fob assembly 10 generally includes a housing 12 and the key 15. The housing 12 generally includes a plurality of electrical components for generating radio frequency (RF) signals to control various operations of the vehicle. The key 15 includes a key blade 14 and a key holder 20. As depicted in FIG. 1, the key blade 14 is positioned in a fully stowed position whereby a channel is disposed within the housing 12 for receiving the key 15.

The key fob assembly 10 includes a releasable button 16 and a plurality of key fob switches 18 a-18 n. The button 16 deploys the key blade 14 from out of the housing 12 of the key fob assembly 10 (as illustrated in FIG. 1 b) in response to being depressed by a user. The key blade 14 is generally configured to pivot to a fully deployed state as illustrated in FIG. 1 c. The key fob switches 18 a-18 n may generally correspond to lock, unlock, panic alarm, liftgate\liftglass release or other suitable operations generally performed by a key fob.

Referring now to FIG. 2, an exploded view of the key fob assembly 10 is illustrated in accordance to one embodiment of the present invention. The button 16 includes a pair of button receiving notches 22 a-22 b. The button receiving notches 22 a-22 b are generally configured such that they are positioned 180 degrees apart from one another. The button 16 includes a pair of button assembly notches 24 a-24 b. The button assembly notches 24 a-24 b are generally configured such that they are positioned 180 degrees apart from one another. The button receiving notch 22 a is generally positioned 90 degrees from each button assembly notch 24 a and 24 b. In a similar manner, the button receiving notch 22 b is generally positioned 90 degrees from each button assembly notch 24 a and 24 b. The button 16 includes a plurality of lips 23. A single lip 23 is positioned between the button receiving notch 22 a and the button assembly notch 24 a. Another lip 23 is positioned between the button assembly notch 24 a and the button receiving notch 22 b. Likewise, an additional lip 23 is positioned between the button receiving notch 22 b and the button assembly notch 24 b.

The key blade 14 and the key holder 20 may be integrated with each other to form the mechanical key 15. Alternatively, the key blade 14 and the key holder 20 may be two separate components coupled together. The key holder 20 generally defines an opening 21 which serves as a pivot axis. A pair of first holder projections 17 a and 17 b are radially positioned about the opening 21 near the top of the key holder 20. The holder projections 17 a and 17 b are positioned 180 degrees apart from each other.

The holder projections 17 and 17 b are generally configured to mate with the button receiving notches 22 a and 22 b, respectively. While the holder projections 17 a and 17 b are mated with the button receiving notches 22 a and 22 b, the key blade 14 is locked and prohibited from rotating to/from the housing 12. A pair of second holder projections 19 a and 19 b are radially positioned about the opening 21 at an opposite end of the key holder 20 (e.g., at the bottom of the key holder 20) from where the first holder projections 17 a and 17 b are located (e.g., at the top of the key holder 20). The second holder projections 19 a and 19 b are positioned 180 degrees apart from each other. The first holder projections 17 a and 17 b are generally positioned 90 degrees from the position of the second holder projections 19 a and 19 b. A button channel 25 is positioned on the bottom of the button 16 (see FIG. 3 a).

A spring 26 is generally coupled to the button channel 25 of the button 16. The spring 26 includes spring coupling members 28 a and 28 b. The spring coupling members 28 a and 28 b are located opposite to each other on the spring 26. The spring coupling member 28 a is generally mated to the button channel 25. The spring coupling member 28 b is generally mated to a spring cover 30. The spring cover 30 includes a cover channel 32 for receiving the spring coupling member 28 b to couple the spring 26 to the spring cover 30. The spring cover 30 includes cover assembly notches 34 a and 34 b and cover receiving notches 36 a and 36 b. The cover receiving notches 36 a and 36 b are generally mated to the second holder projections 19 a and 19 b of the key holder 20 such that the spring cover 32 rotates with the key blade 14 and the key holder 20 as the key blade 14 and the key holder 20 pivots from out of the housing 12 and back to the housing 12.

Referring now to FIGS. 3 a-3 e, perspective views of the assembly process of the key fob assembly 10 is generally shown. As shown in FIG. 3 a, the releasable button 16 is inserted through the opening 21 of the key holder 20. The button 16 is aligned in the opening 21 such that the button assembly notches 24 a and 24 b pass over the second holder projections 19 a and 19 b of the key holder 20. The button receiving notches 22 a and 22 b come into mating engagement with the first holder projections 17 a and 17 b, such that the lips 23 are generally flush with a top portion of the key holder 20.

As shown in FIG. 3 b, the spring coupling member 28 a is mated to the button channel 25 thereby coupling the spring 26 to the button 16. As shown, the spring 26 is in an uncompressed state. As shown in FIGS. 3 c-3 e, the spring cover 30 is aligned over the opening 21 such that the cover assembly notches 34 a-34 b pass over the second holder projections 19 a and 19 b, respectively. The spring cover 30 is coupled to the spring coupling member 28 b of the spring 26 (e.g., the spring coupling member 28 b is mated to the cover channel 32) such that the spring cover 30 compresses the spring 26.

A groove 38 positioned on the spring cover 30 may receive a tool for rotating the spring cover 30 such that the cover receiving notches 36 a and 36 b are rotated towards the second holder projections 19 a and 19 b, respectively. As the cover receiving notches 36 a and 36 b are aligned underneath the second holder projections 19 a and 19 b, the tool may be removed from the spring cover 30 such that the spring 26 pushes the cover receiving notches 36 a and 36 b toward the second holder projections 19 a and 19 b thereby locking the spring cover 30 to the key holder 20. By locking the spring cover 30 to the key holder 20, the spring 26 is loaded to a predetermined torque and compression amount. It is to be noted that the spring 26 is compressed between the spring cover 30 and the button 16 when the spring cover 30 is affixed to the key holder 20. The spring 26 is pre-loaded for rotation while the button 16 is locked (or fixed) to the key holder 20.

Referring now to FIGS. 4 a-4 c, the position of key holder 20 is shown as the key holder 20 (and key blade 14) travels from a stored position to a fully deployed position. FIG. 4 a depicts the key holder 20 being in a stored state (e.g., the key blade 14 and the key holder 20 being disposed within the housing 12 of the key fob assembly 10). In the stored or locked state, the spring 26 is pre-loaded during the assembly process of the key fob assembly 10 as noted in connection with FIG. 3 c-3 e. The first holder projections 17 a and 17 b of the key holder 20 are mated to the button receiving notches 22 a and 22 b of the release button 16, respectively. As shown, in the stored state, the spring 26 is in a compressed state and is pre-loaded to a predetermined torque level while the first holder projections 17 a and 17 b are locked or mated to the button receiving notches 22 a and 22 b of the release button 16.

FIG. 4 b illustrates the key holder 20 being rotated from out of the housing 12 of the key fob assembly 10. In order to initiate rotational movement of the key holder 20 from the housing 12 of the key fob assembly 10, a user applies a downward force on the button 16. The button 16 is generally configured to move in a liner movement (up or down) and is generally not capable of rotating with the key holder 20 and the key blade 14 as the key holder 20 and the key blade 14 rotate from out of the housing 12. In response to the user applying a downward force to the button 16, the amount of compression against the spring 26 increases while the amount of torque across the spring 26 remains the same and begins to decrease as the rotational angle of the key holder 20 increases. In general, the torque generated by the spring 26 decreases as the key blade 14 rotates closer to being in a fully deployed state. During the rotation of the key holder 20 and prior to the key holder 20 being in a fully deployed state, the first holder projections 17 a and 17 b along with the key holder 20 travel along the lips 23 of the button 16. The first holder projections 17 a and 17 b rotate along the lips 23 of the button 16 and are not generally capable of being mated to the button assembly notches 24 a and 24 b, respectively since the button assembly notches 24 a and 24 b are arranged such that the width of each button assembly notch 24 a and 24 b are smaller than the width of each first holder projection 17 a and 17 b. The spring cover 30 rotates along with the key blade 14 and the key holder 20.

FIG. 4 c illustrates the key holder 20 being rotated from the housing 12 of the key fob assembly 10 just prior to the first holder projection 17 a engaging the receiving notch 22 b. The first holder projections 17 a and 17 b are generally configured to rotate 180 degrees in response to the user depressing the button 16 to place the key blade 14 in the fully deployed state. In response to rotating 180 degrees, the first holder projections 17 a and 17 b are mated to the button receiving notches 22 b and 22 a, respectively. The first holder projections 17 a and 17 b while mated to the button receiving notches 22 b and 22 a lock the key holder 20 in the fully deployed state.

To retract the key blade 14 back into the stored position within the housing 12, the user depresses the button 16 thereby disengaging the first holder projections 17 a and 17 b from the button receiving notches 22 b and 22 a and increasing the compression of the spring 26. After the button 16 is released from the key holder 20, the user applies a force to rotate the key blade 14 back toward the housing 12. As the user rotates the key blade 14, the first holder projections 17 a and 17 b travel along the lips 23 of the button 16 and rotate 180 degrees until the holder projections 17 a and 17 b mate with the button receiving notches 22 a and 22 b to lock the key holder 20 in the stored state. While rotating the key blade 14 back to the housing 12, the spring 26 enters into a pre-loaded state (e.g., generates torque) and remains in the pre-loaded state so long as the first holder projections 17 a and 17 b are engaged with the button receiving notches 22 a and 22 b (e.g., the key blade 14 is in the stored position within the housing 12). FIG. 5 depicts an alternate embodiment of the key fob assembly 10′ where the button 16′ is generally non-circular. The visible section of the bottom 16′ may be shaped in any number of circular or non-circular arrangements.

Reference Numeral List 10 Key Fob Assembly 10′ Key Fob Assembly 12 Housing 14 Key Blade 15 Key 16 Button 16′ Button 17a-17b First Holder Projections 18a-18n Key Fob Switches 19a-19b Second Holder Projections 20 Key Holder 21 Opening 22a-22b Button Receiving Notches 23 Lips 24a-24b Button Assembly Notches 25 Button Channel 26 Spring 28a-28b Spring Coupling Members 30 Spring Cover 32 Cover Channel 34a-34b Cover Assembly Notches 36a-36b Cover Receiving Notches 38 Groove

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. 

1. A key fob assembly comprising: a housing; a mechanical key including a key holder for rotation about the housing, wherein the key holder includes first and second sides positioned opposite to each other and the key holder defines an opening extending between the sides for defining a pivot axis to facilitate the rotational movement of the mechanical key; a spring cover coupled to the key holder and positioned about the second side of the opening to rotate with the key holder; a spring positioned within the opening and coupled to the spring cover; and a button coupled to the spring and engaging the key holder to prevent rotational movement of the key holder, the button being disengaged from the key holder in response to a force to enable the key holder and the spring cover to rotate about the pivot axis and the button being non-rotatable while the key holder and the spring cover rotate about the pivot axis.
 2. (canceled)
 3. The key fob assembly of claim 1 wherein the key holder comprises first and second holder projections radially positioned apart and about the first side.
 4. The key fob assembly of claim 3 wherein the button comprises first and second button receiving notches radially positioned thereon and apart from each other for engaging the first and second holder projections to prevent rotational movement of the key holder.
 5. The key fob assembly of claim 3 wherein the button comprises first and second button receiving notches positioned thereon for engaging the first and second holder projections every one hundred and eighty degrees in response to the key holder rotating.
 6. The key fob assembly of claim 4 wherein the first and second button receiving notches are positioned one hundred and eighty degrees from each other.
 7. The key fob assembly of claim 1 wherein the button comprises first and second button assembly notches radially positioned thereon.
 8. (canceled)
 9. The key assembly of claim 7 wherein the keyholder includes first and second holder projections radially positioned apart and about the first side and wherein each button assembly notch is positioned between the first and the second holder projections when the button is engaged to the key holder.
 10. The key fob assembly of claim 1 wherein the spring cover comprises at least one cover receiving notch radially positioned thereon.
 11. The key fob assembly of claim 10 wherein the key holder comprises at least one first holder projections radially positioned thereon and about the second end of the opening, wherein the at least one first holder projection is coupled to the at least one cover receiving notch.
 12. The key fob assembly of claim 1 wherein at least a portion of the button visible to a user is shaped in a non-circular manner.
 13. A key fob assembly comprising: a housing; a mechanical key including a key holder for rotation to and from the housing, wherein the key holder includes first and second sides positioned opposite to each other and the key holder defines an opening extending between the sides for defining a pivot axis to facilitate the rotational movement of the mechanical key; a spring cover coupled to the key holder and positioned about the second side of the opening to rotate with the key holder; a spring positioned within the opening and coupled to the spring cover; and a button coupled to the spring that engages the key holder to prevent rotational movement of the key holder, the button disengaging from the key holder in response to a force to enable the key holder and the spring cover to rotate about the pivot axis and the button being non-rotatable while the key holder and the spring cover rotate about the pivot axis.
 14. (canceled)
 15. The key fob assembly of claim 13 wherein the key holder comprises first and second holder projections radially positioned about the first side of the opening.
 16. The key fob assembly of claim 15 wherein the button comprises first and second button receiving notches radially positioned thereon and apart from each other for engaging the first and second holder projections to prevent rotational movement of the key holder.
 17. The key fob assembly of claim 15 wherein the button comprises first and second button receiving notches positioned thereon for engaging the first and second holder projections every one hundred and eighty degrees in response to rotating the key holder.
 18. (canceled)
 19. The key fob assembly of claim 13 wherein at least a portion of the button visible to a user is shaped in a non-circular manner.
 20. A key fob assembly for a vehicle; the assembly comprising: a housing; a mechanical key including a key holder for rotation to and from the housing, wherein the key holder includes top and bottom sides and the key holder defines an opening extending between the top and bottom sides for defining a pivot axis to facilitate the rotational movement of the mechanical key; a spring cover coupled to the key holder and positioned about the bottom side of the opening to rotate with the key holder; a spring positioned within the opening and coupled to the spring cover; and a button coupled to the key holder and to the spring for preventing rotational movement of the key holder, wherein the button is releasable from the key holder in response to a force and wherein the button is moveable from the top side to the bottom side to compress the spring such that the spring causes the key holder and the spring cover to rotate about the pivot axis for rotating the mechanical key, wherein the key holder and the spring cover rotate independent of the button.
 21. The key fob assembly of claim 1 wherein the key holder includes first and second holder projections positioned apart from each other and about the first side and wherein the key holder further includes third and fourth projections positioned apart from each other and about the second side.
 22. The key fob assembly of claim 21 wherein the first and second holder projections are radially positioned out of phase from the third and fourth holder projections.
 23. The key fob assembly of claim 13 wherein the key holder includes first and second holder projections positioned apart from each other and about the first side and wherein the key holder further includes third and fourth projections positioned apart from each other and about the second side.
 24. The key fob assembly of claim 23 wherein the first and second holder projections are radially positioned out of phase from the third and fourth holder projections. 